Rally Car

Discussion and technical advice for 84-89 AW10 & AW11 MR2. 3A-LU, 4A-GE, 4A-GZE.

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aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

gon wrote:I have the MK2 MR2 (non-ABS) and it does a good job.


Is it only the MC that is required? I.e. is the standard servo retained?

I'll post the price of the final drive as soon as the bill arrives. Elite have assured me that it will be substantially cheaper than the £1200 asked by Kaaz and Jubu and of equal quality.
gon
Posts: 78
Joined: Thu Jan 31, 2008 1:50 pm

Re: Rally Car

Post by gon »

yup , only MC ....
Servo stays the same ... assuming you have a mk1b ?
aw11rally
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Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

The rally car is a 1a.
gon
Posts: 78
Joined: Thu Jan 31, 2008 1:50 pm

Re: Rally Car

Post by gon »

I will take some pics and dimensions tomorrow of the mounting points ...
gon
Posts: 78
Joined: Thu Jan 31, 2008 1:50 pm

Re: Rally Car

Post by gon »

Just found this comment by Paul Woods on another forum
"
Bear in mind mk1's have two different MC mounting patterns, either 2 bolt or 4 bolt fitting.... but it is just the Mk1a that has the two bolt fitting (mk2 has 4 bolt), so if you want to fit a mk2 MC to a mk1a you need to fit a mk1b servo first.
"

I will measure and take pics of my one in a couple of hours, but it looks like you are going to need the mk1b servo and the mk2 non-abs 15/16ths MC
aw11rally
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Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

Cheers gon, I found the same thing last night. Luckily I've got a 1b servo and MC knocking about somewhere. I'm thinking of going for the 1" MC from a Previa in an attempt to make the brakes more easy to modulate. At present they require very little force (but a lot of travel) to lock. Also we currently require a risidual pressure valve in the front lines, without this the front brakes require two pumps of the MC to get enough fluid through the 4pots.

Ideally I want a brand new MC, I couldn't find a 15/16ths anywhere, conversely the Previa 1" MC seems readily available.
BIGBOBO
Posts: 531
Joined: Sun Dec 02, 2007 1:05 am
Location: Belgium

Re: Rally Car

Post by BIGBOBO »

A bit off topic but is there a difference between LHD and RHD brake servo's and master cylinders?

I need to upgrade mine and it's far easier to find parts in the UK.
stenky
Posts: 356
Joined: Wed Mar 23, 2011 9:04 pm
Location: Slovakia

Re: Rally Car

Post by stenky »

yes it is. LHD and RHD MC pipe outlets are on opposite sides. i have encountered the same challenge after getting a RHD MC for my LHD car. you either have to try re-bending your current pipes, have new ones made or get a pair of custom braided flexible brake hoses with correct fittings (this is what I have done)
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aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

BIGBOBO wrote:A bit off topic but is there a difference between LHD and RHD brake servo's and master cylinders?

I need to upgrade mine and it's far easier to find parts in the UK.


Whilst searching the web for toyota parts bin options it does seem that there are MC with opposite fittings. Can't remember which had wrong outlets for RHD mk1 maybe supra or landcruiser. There seems to be a lot of MC talk on 4x4 forums, it sounds like a lot of toyota MCs are interchangeable.

Sorry, very vague I know!
BIGBOBO
Posts: 531
Joined: Sun Dec 02, 2007 1:05 am
Location: Belgium

Re: Rally Car

Post by BIGBOBO »

stenky wrote:yes it is. LHD and RHD MC pipe outlets are on opposite sides. i have encountered the same challenge after getting a RHD MC for my LHD car. you either have to try re-bending your current pipes, have new ones made or get a pair of custom braided flexible brake hoses with correct fittings (this is what I have done)


Thanks for the info. Were did you get the hoses and what kind of fitting do they need?
stenky
Posts: 356
Joined: Wed Mar 23, 2011 9:04 pm
Location: Slovakia

Re: Rally Car

Post by stenky »

i used these: http://www.brake-lines.co.uk/

swivel male M10x1mm fittings at both ends, both angled 90*, 355mm length. i am not sure about the length though, maybe i could have ordered a bit longer hoses. haven't fitted mine yet. i should be able to confirm fitment as soon as i get a second car. aw11 serves as my daily now, which is the worst thing if you mean to modify :D

edit: pic

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aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Quick Gearbox Update

Post by aw11rally »

Right, its been a while so I thought I'd post a quick update about the gearbox.

The box has been with Elite Racing Transmissions for about three weeks now. on inspection Elite found a few problems that we were not already aware of. As expected the synchro ring on 2nd gear is knackered but there is also a missing roller on one of the under gear bearings and the plastic inserts on two of the selector forks are completely worn away.

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As a result of the findings I have ordered a full set of synchros and synchro hubs (updated/up rated design), a full set of under gear bearings and an LSD install kit comprising taper bearings and seals. This little lot should arrive from the states in a week or so (allowing for time in customs!).

Elite have offered to modify the selector forks by welding in extra metal where the plastic sliders sit then machining back to the original profile. They say this is a tried and tested solution that they use regularly when building race boxes.

Elite's design team are currently working on the final drive kit, I am yet to hear what ratio they can squeeze in.

So by the end of the month we will hopefully have a fully rebuilt / refreshed C64 gearbox with a 5ish:1 final drive.

Once the box is back in we will be on the hunt for new seats and belts as the current items are now out of date. In the meantime I will be mostly playing with my new toy, a Ford P100 pickup with all the bits from a Sierra Ghia added, including the DOHC engine, MT75 gearbox and full electrics pack (windows, mirrors, roof, heated front screen). So far I've given it a full service, including HG, water pump and thermostat. I've also started the rust protection, these rust as impressively as a Mk1 MR2, I'm determined to win the fight.
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aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Gearbox update

Post by aw11rally »

Look what arrived today.
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All the bits to rebuild a C64. Diff bearings, diff seals, input shaft seal, under gear bearings and a full set of 2003+ synchro bits (the better ones).

I had them delivered to work, they arrived via UPS on time and in perfect condition. Unfortunately they also arrived with a bill of £157 for import taxes, Ouch!!!!

Luckily I managed to escape work for an hour and take the bits up to Elite to have them all put in the right place. I had a chat with the design guy there and it looks like we'll be getting a 5:1 final drive to go in the nicely refreshed gearbox.
smokeejoe
Posts: 85
Joined: Wed Sep 29, 2010 11:34 pm
Location: Norfolk, england

Re: Rally Car

Post by smokeejoe »

excellent thread, i have a hilux surf master cylinder sat in my workshop if you need any measurements for fitment let me know.
aw11rally
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Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

smokeejoe wrote:excellent thread, i have a hilux surf master cylinder sat in my workshop if you need any measurements for fitment let me know.


Thanks mate.

What bore is the hilux MC? Is it a two or four bolt flange?
aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

The box of gears is finished.

Post by aw11rally »

I collected the gearbox from Elite yesterday. It is now in pride of place in the kitchen.
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Speed graphs.
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Standard C64 FD of 4.529 (15in slicks)

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5.0 FD (15in slicks)

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5.0 FD (13in slicks)

Due to the rather cramped C64 diff casing 5.0 was the shortest CWP that could be squeezed in. This gives us two setup options. 15in slicks and short suspension travel for long, smooth flowing stages such as those at Anglesey. 13in slicks and long suspension travel for tight bumpy stages such as Weeton Barracks and Trawsfynydd.

I'm still on the hunt for some 13x7in motorsport wheels such as compomotive in 4x100. Another option would be to go down the hubcentric adapter route on the rear and borrow some 4x108 wheels off a mate. Low / 0 offset usually though so escort Mk2 wheels may poke out the arches slightly.
smokeejoe
Posts: 85
Joined: Wed Sep 29, 2010 11:34 pm
Location: Norfolk, england

Re: Rally Car

Post by smokeejoe »

the hilux MC is 1" it has a 4 bolt flange, if you need anything else please let me know.
i have 2 of these in my workshop, so we could have a deal if you wanted to use 1.
aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

smokeejoe wrote:the hilux MC is 1" it has a 4 bolt flange, if you need anything else please let me know.
i have 2 of these in my workshop, so we could have a deal if you wanted to use 1.


Cheers, I'll PM you.
aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Thread Revival

Post by aw11rally »

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It's been a while but I thought a thread revival was in order. Especially as we've been tinkering recently. But first some videos from a few years back, when we actually competed on a regular basis in the wee six speed mk1.

http://youtu.be/8Hlso4Gsqmk

http://youtu.be/HN8MDUSQJKA
aw11rally
Posts: 763
Joined: Wed Dec 31, 2008 12:46 am

Re: Rally Car

Post by aw11rally »

After a couple of seasons out due to moving house and now with a baby on the way it's time to get the MR2 back on the road / track before it's too late.

Last weekend saw the fully freshened LSD C64 refitted. Now sporting a custom 5.1 final drive, new bearings, synchros and hubs and modified selector forks (plastic bits replaced with weld and machined to the correct profile).

The box was filled with "running in oil" (Gulf Competition stuff none less) and the engine fired up whilst securely raised on stands. The ratios feel pretty good, let's just say we're now unlikely to exceed 120mph in 6th before hitting the limiter. We might actually use all six gears in anger, not just the first three.

A few little jobs to do but nothing more than a drivers seat and belts for the MOT. Then some gentle road miles to bed the new synchros in.
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